Coil winding machine



Nov. 4, 17. R. M. CONKLIN COIL WINDING MACHINE Filed Aug. 22, 1945 4 Sheets-Sheet l ATTORNEY Nov. 4], 1947. R. M. CONKLIN 2,430,105

COIL WINDING MACHINE Filed Aug. 22, 19 45 4 Sheets-Sheet 3 l/vyawrax RM. GONKL M A TTORNEV Nov. .4, 1947; R, M, C QKLW 2,430,105

con. WINDING MACHINE Filed Aug. 22, 1945 4 Sheets-Sheet 4 IN VEN TOR RM. CON/(LIN A 7' TORNEY Patent ed Nov. 4, 1947' orrlca COIL WINDING MACHINE Robert M. Conklin, West Newbury, Masa, asslgnor to Western Electric Company, Incorporated, New York, N. Y., a corporation of New York Application August 22, 1945, Serial No. 611,933

This invention relates to coil winding machines, particularly those of the toroidal winding type and the primary object of the invention is a machine for winding such coils in which the wire is maintained under substantially constant tension throughout the winding operation.

Present standard machines of this general type have winding rings equipped with wire guides and supplies of wire and traveling in circular paths which extend through the annular cores upon which the wires are being wound. Duringthe travel of the wire guide in each instance to the point farthest from the core, a length of wire is withdrawn from the ring to form one turn on the core. This length of wire in standard practice forms a loop during the travel of the wire guide from its position farthest from the core to its position after it has passed through the core. This loop is 'carried around and then suddenly pulled tight on the core thereby subjecting the wire to a sudden and abnormally high tension, Before the loops are tightened, the wire is free to whip fromside to side and frequent overlapping 01' the turns occurs often to the extent of increasing the cross-sectional area of the coil by twenty or thirty per cent.

It is, of course, desirable to make these coils as small and compact as possible and this is particularly truewhen they are to be used in military communication systems where minimum volume and weight are of primary importance.

The size of a coil of given electrical constants is largely determined by the diameter of the wire used and the size of central aperture of the finished coil. The aperture cannot be reduced beyond the diameter required for the passage of the wire guiding structure and with existing machines the wire must be at least number 38 (A. W. G.) in order to withstand the tension imposed on it when the loops are tightened.

Attempts have been made to control the loops by pulling them between spring backed plates before the wire passes to the core, but insofar as applicant is aware, none of these expedients have been successful in eliminating either the pverlapping of the turns or the high tension produced when the loops are tightened on the core.

having a portion to guide the wire from the shuttie and around portions of the core, to create a Claims. ((71. 242-4) constant tension in th wire and eliminate the formation of a loop therein.

More specifically, in one embodiment of the invention, a flyer is formed with a plurality of fins and is slidably mounted to travel on one side oi. the shuttle due to the force applied to it by jets of air directed toward the fins. This force causes the fiyer to travel at variable speeds during the constant speed travel of the shuttle and creates a constant tension in the wire during the winding of each tum.

In another embodiment of the invention, the fluid driven flyer is caused to drive the shuttle through a pull on the wire necessary to create the the exception of a brake applying means.

. drag on the shuttle to vary the tension created in the strand by the fiyer pulling the strand from the shuttle.

Another species of the invention includes a iiyer formed of relatively movable members mounted for movement on the shuttle, portions being provided at adjacent ends of the flyer for the traveling of the wire from the shuttle to the core. The leading fiyer member is provided with fins so that it may be driven by a fluid under pressure while the trailing member must be pulled by the wire. The frictional contact between the trailing member and the shuttle during the driving of the leading member by air under pressure results in the irregular movement of the iiyer members in their circuitous path to maintain a constant tension on the wire.

Other objects and advantages will be apparent from the following detailed description when considered in conjunction with the accompanying drawings, wherein Fig. 1 is a fragmentary side elevational view of one species of .the toroidal coil winding machine;

Fig. 2 is a fragmentary top plan view taken along the line 2-2 of Fig. 1;

Fig. 3 is a fragmentary detailed view taken along the line 3-3 of Fig. 2;

Fig. 4 is an enlarged sectional view of the shuttle and flyer;

Fig. 5 is an enlarged fragmentary side elevational view of .the flyer;

Fig. 6 is a fragmentary sectional view taken along the line 6-6 of Fig. 5;

Fig. 7 is a schematic illustration of thirty-six positions of the flyer during constant shuttle velocity;

Fig. 8 is a schematic illustration of a plurality of positions of the flyer during given positions of the shuttle;

Fig. 9 is a graphical illustratlon oi the travel of the flyerduring one revolution of the shuttle;

Fi'g. 10 is a schematic illustration of another species of the invention wherein the fluid driven flyer drives the shuttle;

Fig. 11 is a top plan view of the structure shown in Fig. 10;

Fig. 12 is a schematic illustration of another species of the invention with the slider employed in conjunction with the fluid driven flyer; and

Fig. 13 is a similar view of the structure shown in Fig. 12, but with the flyer and slider at different positions.

Referring now to the drawings, attention is first directed to Figs. 1 to 6 inclusive, which illustrate one species of the invention.

In view of the fact that toroidal coil winding machines are well known, only those portions of the machine necessary to illustrate the invention are shown.

The annular core upon which wire 2! is to be wound is held in a chuck or clamp 22, the latter being supported for movement in a given path to repeatedly rotate the core 20 about its axis, a given number of one-half revolutions to cause distribution of the wire thereon.

The wire 2| in the present instance is a. number 40 wire. A supply of this wire is stored upon a shuttle 24 in the conventional manner. In other words, the shuttle 24 may be provided with a section which is removable for the mounting of the annular core 20 in the chuck 22 with the shuttle extending substantially through the center of the core. After this has been accomplished, the shuttle may be driven in a reverse direction, from that in which it will be driven during the operation of the machine to wind the wire on the core, to fill the shuttle with a quantity of wire necessary for the coil to be wound therefrom. The shuttle is provided with gear teeth 25 at its inner periphery for interengagement with teeth of a gear 26. The gear 26 is mounted upon a shaft 21 which may be driven in reverse directions by any suitable means (not shown). Idler rollers 28 have their Deripheries grooved at 29 to receive the teeth 25 of the shuttle 24 and to cooperate with the gear 26 in supporting the shuttle for rotation about its axis. The rollers 28 are mounted upon shafts 30, the'latter being journall'ed in suitable bearings of a supporting structure (not shown). An annular projection or track 32, having a dovetail cross-sectional contour, as illustrated in Fig. 4 is formed at one side of the shuttle, including the removable section thereof, to provide a circu- 'lar and continuous track for a flyer 34.

The flyer 34 is light in weight. yet sufliciently durable in structure to control the winding of the wire to the core. The flyer 34 has a general arcuate contour with inwardly projecting edges 35 to conform to the track 32. There is sufiicient clearance, however, between the flyer and the track for free movement of the flyer relative to the shuttle. Fins 3B, stamped out of the material of the flyer, project outwardly at like angles as shown in Fig. 2. The leading end of the flyer is provided with a hook member 38 and a sheave or wire guide 39 to control the wire passing from the shuttle to the core as illustrated in Fig. 2.

Means is provided to direct a fluid under pres-' sure to the fins 36 of the flyer to cause the flyer to travel on its track about the shuttle and through the core 20. This means includes the plate 40, cylindrical in general contour, but having a cutaway portion at 4| to allow for the movement of the chuck 22 from its solid line position (Fig. 2) to its dotted line position, The plate 40 has a multiplicity of passageways 42 disposed in circular arrangement about the center oi the plate which is in alignment with the center of the shuttle. The passageways 42 extend diagonally through the plate as illustrated in ljig. 2 for a purpose hereinafter described. The plate 40 is secured to a housing 44 by screws 45 to completely close the open side of the housing. The housing 44 conforms, in general, to the plate'40, it also having a cutaway portion 46 to allow for movement of the chuck 22. A hollow portion 41 of the housing 44 communicates with a passageway 48 in a hollow shank 49. The shank 49is threaded for a portion of its length and extends through an aperture in an arm 50 where it is secured in place by the aid of a nut 5|. A flexible hose 52 has one end secured by the aid of a clamp 53 to the outer end of the hollow shank 49, the other end of the hose being connected to a suitable fluid supply through a variable drive pump or other means 54. The arm 50 is pivotally supported at 55 upon a stationary member 51 and is normally held in the position shown by the aid of a spring 58. To facilitate in the loading of the machine, it is possible to move the structure supported by the arm away from the shuttle and chuck.

During the operation of this embodiment of the invention, let it be assumed that the shuttle is loaded with a supply of the wire 2| and that a core- 26 is mounted in the chuck 22 with the chuck at the starting position. The leadin end of the wire is threaded beneath the hook or guide 38 and around the sheave or guide 39 after which it is secured in a conventional manner to the core. By operating a valve 50 in the fluid supply line, and starting the driving means for the shuttle, the machine will begin its operation. The fluid in the present instance is air under pressure which is forced in jets through the passageways 42 to impinge upon the flns 36 and thus provide a driving force for the flyer 34, which is variable with variation in the pressure of the fluid. It will be noted that the openings in the flyer formed by the pressing out of the flns provide pockets which are closed by the fiat surface of the shuttle or track 32, The openings, therefore, do not provide outlets for the jets of air, but serve to provide pockets for the jets of air. Through the constant application of the driving force, namely, the fluid or air under pressure to the flyer, the latter is driven at a speed controlled by the wire 2|.

During the travel of the leading end of the flyer from a position adjacent the core to a position farthest from the core, a length of wire is being withdrawn from the shuttle to form the next turn of the wire on the core. During this interval, the flyer is traveling slower than the shuttle, the latter being driven at a constant rate of speed. As the flyer passes this position farthest from the core, a loop could be formed in the wire if the flyer traveled at the same speed as the shuttle. However, the constant application of the driving force to the flyer will cause it to travel at a, faster rate of speed applying a constant tension on the wire to eliminate the formation of the loop. This point is illustrated in Fig. 9 where the dotted line illustrates the constant shuttle velocity, while the curved line illustrates the varying velocity of the flyer from its number one position shown in Fig. 8, represented by the triangular members through one complete cycle and back to the number "one position. During the first four positions,

the fiyer is traveling slower than the shuttle, while during the last four positions, the speed of the fiyer is increased so that it will constantly control the wire and eliminate the formationof the loop.

fA further illustration is given in Fig. '7 showing thirty-six positions of the fiyer with like time intervals therebetween during constant shuttle velocity. In Fig. 8 a fewer number of positions of the fiyer are illustrated by the triangular members during the constant velocity of the shuttle, the wire takeoff portions of the shuttle illustrated by the circular members with the numbers I to 8' shown therein.

The species shown in Figs. 10 and 11 embodies the same principles shown in Figs. 1 to 6, inclusive, and like reference numerals are directed to identical parts. The only difference between this species and that shown in Figs. 1 to 6, inclusive, is the driving means for the shuttle. In this structure, the shuttle is driven bythe strand and the pull applied thereto through the movement of the fiyer. The fiyer is driven in the same manner by the Jets of air under pressure. It is desirable, therefore, to provide free rotating supports for the shuttle in the form of the rollers 28 and a gear 10. The gear I0 is mounted for free rotation upon a shaft 7i and interengages the teeth 25 of the shuttle 24. A suitable brake member 12 carried by a disk 13 supported against rotation on the shaft ii will apply a variable braking force on the gear l0 depending upon the force of a spring 76. The spring M is disposed concentric with the shaft H and interposed between the member 13 and a washer 15. Lock nuts 76 disposed upon a threaded portion ll of the shaft may be adjusted to vary the force of the spring. Through this structure, a constant tension may be created in the wire which may require little braking force at the gear 10, added to the force necessary to rotate the shuttle through the pull on the wire. Otherwise, the operation of this species of the invention is identical to that of the structure shown in Figs. 1 to 6, inclusive.

The structure of the species shown in Figs. 12 and 13 is substantially identical with that shown in Figs. 1 to'6, inclusive, the only difference lying in the structure of the fiyer. The shuttle being identicalin structure to the shuttle M is given the same reference numeral. The fiyerin this structure differs from the fiyer 3% in that it is formed of two separate portions 80 and 8|. Furthermore, a guide 82 and a sheave 83 are mounted adjacent the rearmost end of the portion at instead of at the leading end thereof; This portion is provided with fins 86 identical with the fins 36 and both portions of the fiyer are formed to ride on the track 32 of the shuttle. .The per-- tion 80 is similar in structure to the portion M with the exception of the provision of fins therein. A sheave 85 is mounted upon the portion 80 adjacent the leading end thereof to receive the wire from the sheave 83. During the operation of this structure, it should be assumed that the shuttle is traveling at a constant speed and that the jets of air are causing movement of the fiyer portion 8| at a speed controlled by the wire and the fiyer portion 80. Although the portion 80 is formed to move freely on the track 32 of the shuttle, the

travel must be increased rapidly to maintain the constant tension on the wire. With this structure, the fiyer portion 80 assists thefiyer portion ill in maintaining the constant tension on the strand by lagging behind as illustrated in Fig. 13. Although a loop is formed in the wire extending about. the guides 83 and 85, there does-not exist a loose loop or a portion of the wire whichis out of control of the fiyer. Furthermore, there will be no Jerking or snapping of the wire, which would exist in the forming of a loose loop. The frictionally supported, air driven fiyer, although described as consisting of two parts, may be further defined as fiyer 8i and a slider so; Considering the fiyer portions in this manner, they actas a cu'shioningmeans for the wire, making it possible for the wire to drag the slider portion 80 toward the main fiyer portion 8i should the ten- SiOn in the wire be caused to increase at any point during the circular travel of the fiyer. In operation, the portions 80 and Bi abut each other adjacent the dotted line positions shown in Fig. 12, but as they begin their travel toward the core, where the loop in general practice begins to form, the portion or slider 80 will lag behind as the fiyer portion BI is urged onward at a more rapid rate of speed to maintain the. constant tension in the wire and uniformly lay the wire on the core.

Although specific improvements of the invention have been shown and described, it will be understood that they are but illustrative and that various modifications may be made therein without departing from the scope and spirit of this invention as defined by the appended claims.

' What is claimed is:

1. In a toroidal coil winding machine, a rotatable support for an annular core on which a wire is to be wound, an annular shuttle for a supply 01 the wire, means supporting the shuttle in a position at right angles to the core for rotation in a circular path extending substantially through the center of the core and about a fixed axis, a fiyer mounted for movement in a like circular path relative to the shuttle and having a portion to guide the wire from the shuttle around portions of the core, a fin carried by the fiyer, and means to direct a fluid under pressure to contact the fin and cause the flyer to move in its circular path to apply a, constant tension on the wire being wound on the core.

existing resistance therebetween will cause it to 2. In a toroidal coil winding machine, a rotatable support for an annular core on which a wire is to be wound, an annular shuttle for a supply of the wire, means supporting the shuttle in'a positionat right angles to the core for rotation in a circular path extending substantially through the center of the core and about a fixed axis, a fiyer mounted for movement in a like circular path relative to the shuttle and having a portion to guide the wire from the shuttle around portions of the core, and means to apply a constant driving force to the fiyer to cause the fiyer to wind the wire under a constant tension on the core.

3. In a toroidal coil winding machine, a rotatable support for an annular core on which a wire is to be wound, an annular shuttle for a supply of the wire, means supporting the shuttle in a position at right angles to the core for rotation in a circular path extending substantially through the center of the core and about a fixed axis, a

fiyer mounted for movement in a like circular path relative to the shuttle and having a portion to guide the wire from the shuttle around portions or the core, and means to app y a conment of the flyer at variable speeds to wind the wire under a variable constant tension on the core.

4. In a toroidal coil winding machine, a rotatable support for an annular core on which a wire is to be wound, an annular shuttle for a supply of the-wire, means supporting the shuttle in a position at right angles to the core for rotation in a circular path extending substantially through the center of'the core and about a fixed axis, a flyer mounted for movement in a like circular path relative to the shuttle and having a portion to guide the wire from the .shuttle around portions of the core, a nu carried by the flyer, and a fluid control member having a substantially circular arrangement oi passageways todirect jets of a fluid under pressure toward the path of the flyer to contact the fln and cause the flyer to move in its circular path to wind the wire on the core under a constant tension.

5. In a toroidal coil winding machine, a rotatable support for an annular core on which a wire is to .be wound, an annular shuttle for a supply of the wire, means supporting the shuttle in 'a position at right angles to the core for rotation in a circular path extending substantially through the center of the core and about a fixed axis, a 'flyer mounted for movement in a like circular path relative to the shuttle and hav ing a portion to guide the wire from the shuttle around portions of the core, a fin carried by the fiyer, a fluid control member having a substantially circular arrangement of passageways to direct jets of a fluid under pressure toward the path of the flyer to contact the fin and cause the flyer to move in its circular path to wind the wire on the core under a constant tension, and means to support the fluid control member for movement away from the fiyer.

6. In a toroidal coil winding machine, a rotatable support for an annular core on which a wire is to be wound, an annular shuttle for a supply of the wire, means supporting the shuttle in a position at right angles to the core for rotation in a circular path extending substantially through the center of the core and about a fixed axis, a. flyer mounted for movement in a like circular path relative to the shuttle and having a portion to guide the wire from the shuttle around portions of the core, a fin carried by the flyer, a fluid control member having a substantially circular arrangement of passageways to direct, jets of a fluid under pressure toward the path of the'flyer to contact the -fln and cause the flyer to move in its circular path to wind the wire on the core under a constant tension, means to support the fluid control member for movement away from the flyer, and means to normally hold the member adjacent the shuttle and parallel with the path of the fiyer.

7. In a toroidal coil winding machine, a rotatable support for an annular core-on which a wire is to be wound, an annular shuttle for a supply of the wire, means supporting the shuttle in a position at right angles to the core for rotation in a circular path extending substantially through the center of the core and about a fixed axis, a

v stant variable force to the flyer to cause move- 8 flyer having a portion to guide the wire from the shuttle around the core, a circular track on the shuttle for the flyer, and means to apply a constant driving force to the flyer to cause the liver to wind the wire under a constant tension on the core.

8. In a toroidal coil winding machine. a rotatable support for an annular core on which a wire is to be wound, an annular shuttle for a supply of the wire, means supporting the shuttle in a position at right angles to the core for rotation in a circular path extending substantially through the center ofthe core and about a fixed axis, a flyer having a leading portion and a trailing portion both movable in a circular path relative to the shuttle through the core, a guide member on the leading flyer portion to receive the wire from the shuttle, a guide member on the trailing flyer portion to receive the wire from the leading flyer portion and guide it to the core, means to drive the leading flyer portion to cause winding of the wire on the core, the trailing flyer portion being driven by the wire.

9. In a toroidal coil winding machine, a rotatable support for an annular core on which a wire is to be wound, an annular shuttle for a supply of wire, means supporting the shuttle in a position at right angles to the core for rotation in a circular path extending substantially through the center of the core and about a fixed axis, a flyer having a leading portion and a trailing portion both movable in a circular path relative to the shuttle through the core, a guide on the leading flyer portion to receive the wire from the shuttle, a guide member on the trailing flyer portion to receive the wire from the leading flyer portion and guide it to the core, a. fin carried by the leading flyer portion, and means to direct a fluid under pressure to contact the fin and cause the leading flyer portion to move in its circular path to apply a constant tension on the wire, the trailing flyer portion being driven by the wire.

10. In a toroidal coil winding machine, a rotatable support ior an annular core on which a wire is to be wound, an annular shuttle for a supply of the wire, means supporting the shuttle in a position at right angles to the core for rotation in a circular path extending substantially through the center of the core and about a fixed axis, a flyer mounted for movement in a like circular path relative to the shuttle and having a portion to guide the wire from theshuttle around portions of the core, a fin carried by the liver, means to direct a fluid under pressure to contact the fin and cause the flyer to move in its circular path to apply a constant tension on the wire being wound on the core, and means to vary the pressure of the fluid to vary the tension on the wire.

ROBERT M. CONKLIN.

REFERENCES CITED The following references are of record in the file of this patent:

UNITED STATES PATENTS Number Name Date 2,230,363 Pash Feb. 4, 1941 89.1305 Atwood Jan. 15, 1907 

